Building a cage

[Phil_S]

I've built several amps that need enclosures or other external improvements. I've decided to get into a cleanup effort to complete the projects.

This one is basically a vibrochamp. Tremolo is on the toggle switch. I really ought to do it right with a jack for a footswitch, but that's not the question. BTW, the Telefunken EL95 (6AQ5) demanded that I build this amp for it. This amp has tremolo "to die for."

The amp has too much exposed. I think you can see the way the OT is with terminals and wires and such. I'd like to put a cage on top of this amp. I'm thinking it should just go on top of the whole thing. More or less, I'm thinking of it like a top chassis, bent, corners closed, lips out to screw into the wood. (The wood looks like walnut, but it is just a decent looking piece of dark poplar.)

I don't know how to fabricate a cage that will look decent and stand up over time. What material? Where to get it? How to get it shaped? Does it need an internal frame? Most of all, do it on the cheap!

I was initially thinking about a metal cage. Should I scrap that for a vented wood box that's open at the bottom? A couple of wood "straps" on the side would close it up nicely. Surely my woodworking skills and tools are better suited to this than my metal fabricating ability.

The metal chassis measures 12.25" x 6.875".

Thanks for any thoughts you might share.

Phil

[Cantplay]

Perforated steel, or aluminum.

Bend it along a row of holes.

You can also use heavy gauge wire screen.

You could make a wooden frame and add a grill similar to steam radiator civer.

John

[Phil_S]

Cantplay: Your handle reminds me of me! Thanks for the thoughts.

For perforated metal, how do I get the corners (sides) to look nice and feel smooth? Is it like folding a cardboard box with long lips on the inside?

Or maybe just a U shaped bend and use wood for the ends?

Honestly, I'm having trouble visualizing on this.

[Gibsonman63]

I have a couple of sets of wedge monitors where the grills are perferated metal inserted into channel in the wooden frame then screwed in. Of course, black grills on black carpeted wood with black screws is pretty forgiving.

Maybe a variation on the theme.

[Phil_S]

GM: That's good, really good. I think I can work with that! Thanks.

[Geeze]

To make the edge straight and smooth with metal press brake would be the best bet. A brake is basically a big pair of wide vise grips with a rigid flat plate that bends the material against the 'grips'. If you find a grill or plate you like call around to sheet metal shops and see what they would charge per bend. I'd recommend some consultation before you layout the bends as the gauge and material will play into the dimensional 'loss' of the bend itself.

Or you could replace the side wood pieces with a wood shell.

[M Fowler]

You could do it like People's Amp did his outer large piece with small inner piece the cage material is screwed to.

[Cantplay]

I like the winding band on that.

Next project I think I want to do a stringbox cab.

John

[Phil_S]

Mark: I like those and I think I can do that. I don't have a full wood shop. Any power tool sawdust has to be made outside. Looks like I just have to rabbet around 3 sides and then run the roundover bit on it. Too bad I'll have to remove the nice poplar I've got on it now.

I think time is going to run out on the outside work and this will get saved for the spring unless I get lucky.

Foolishly, I thought I'd renovate a bathroom on my own and now that's I've started I have to concentrate on finishing. It is just floor, toilet, and sink. The old floor is vinyl sheet goods on concrete slab and it's been there over 25 years. The glue is holding far better than I imagined, so the sheet goods leaved a layer of paper when it separates and it is awful to deal with. I did not allow for such a difficult time removing the old floor. I'm reduced to a heat gun and 2" scraper. Nothing else seems to do the job. It is a good thing the whole floor is only 54 sq ft. I figured 1-2 days for removal. It is more than that and at my age, I didn't consider how hard it is to be on my hands and knees for hours at a time. Getting older sucks.

At this point I'm ready to spend the money to rent a machine to do the removal, but I don't actually think I can get it into the bathroom effectively because the room is less that 6' wide. Besides, I'm half done with the floor. Argh!

[M Fowler]

A large two handed angle grinder with one of those large round wire brush chucked up should do the job after you scrap the hell out of the vinyl. What a miserable job. Don't forget to get a new johnny ring for that toilet buddy.

Two pieces of wood cut with sabre saw should do the trick on each end. I would attached from the side rather then from the bottom plate like People amp does it.

[Phil_S]

Mark: On the bathroom, I'm more than half way removing the floor. I measured it again this morning because memory is not reliable and I needed a sense of progress. The room is not quite 6' wide and only 9' long, from which you subtract 7 1/2 sq ft for the (tiny) shower. So the whole thing is just 45 sq ft.

I think I'm going to tough it out with the floor bully, the hand tool, and the heat gun. Thanks for the advice and I did look closely at one of those grinders at the home despot yesterday. My fear is that I'll cut grooves in the concrete and that I'll be sorry. LOL, they will rent you a great power floor tool that is too heavy for one person to lift (maybe 100#) for about $50 and sell you the attachment for it for over $100, oh -- I don't think it will fit in the room very well.

On the amp, it is good that the existing panels on that amp attach from the side, so making new panels should actually be a snap because the existing ones will make a perfect template. I don't have a scroll saw. This will get done with a circular saw (to a square) and then with the router to radius the upper corners, cut the rabbet, and a little 1/8" roundover to take the edge off. It looks like a perfect plan. Maybe we will have an extended fall and I'll squeeze this in. I've also got to buy some decent looking wood. I'll go to the exotic wood place and buy a "short" for not very much money.

[M Fowler]

Okay I'll sit down to watch this all unfold then, good plan, now stick to it.